Synthetic filament yarn

ABSTRACT

A YARN COMPRISING A BLEND OF NOT LESS THAN 70% OF DELUSTERED FILAMENTS AND NOT MORE THAN 30% OF BRIGHT FILAMENTS WHEREIN THE DELUSTRED FILAMENTS CONTAIN NOT LESS THAN 0.7% BY WEIGHT OF A DELUSTRANT (TIO2) AND THE BRIGHT FILAMENTS CONTAIN LESS THAN 0.3% OF SAID DELUSTRANT.

United States Patent 'lfice 3,608,291

Patented Sept. 28., 1971 merits containing not less than 0.7% by weight of a deggEig YARN lustrant and not more than 30% of bright filaments con- Malcolm Carnie Cobb, Anthony Charles Davis, and tammg less than 03% 9 the delustrant Kazimierz wiktol. Mieszkis, Pontypool, England, The term filament includes both continuous filaments signors to Imperial Chemical Industries Limited, Lonand filaments 1n Staple fibre q d E l d Preferably the delustrant is titanium dioxide and the No Drawing. Filed May 19, 1969, Ser. No. 826,017 smaller proportion of yarn contains not more than 0.05% Claims priority, application Great Britain, May 24, 1968, b Weight f hi d l t t,

24,933/63 The present invention is especially applicable to poly- Dozg 3/04 3/22 10 amide yarns and the polyhexamethylene adipamide yarns US. Cl. 57--140 8 Claims in particulan A polyamide yarn suitable for use in carpets comprises ABSTRACT OF THE DISCLOSURE 85% of filaments containing 1% titanium dioxide and of filaments containing 0.02% of titanium dioxide. A y rn mp g a blend of not 1eSS than 70% of 15 Blending is most satisfactorily achieved when the filadelustered filaments and not more than 30% of bright ments are in staple fibre form. Blending may, however,

filaments wherein the delustred filaments contain 110i be carried out using continuous filament yarns by douless than 0.7% by weight of a delustrant (TiO and bling especially at spinning, for example. The unevenness the bright filaments contain less than 0.3% of said deof blending which may result from doubling is improved lustrant.

by subjecting the yarns to a bulking treatment e.g. stuifer box crimping, which treatment is normal procedure for The present invention relates to improvements in syncarp y of both Staple fibres and cohthlllolls thetic filament yarns and is especially concerned with mehtsth improvement i appearance f yams heavily The bright, sparkling effect of the filaments containing l d to i mp ili fi t the smaller proportion of titanium dioxide, that is the The anti-soiling efiect of highly delustred yarns using, br ghf filamen y e enhanced y Using filaments f l i i di i is Well known; however having a trilobal cross-section. Apreferred yarn comprises h h yarns are d they acquire a rather a blend of polyhexamethylene adipamide staple fibres in pleasant, chalky frequently called dead, appearance. This Which one Component, formihg by Weight offhe h lk appearance f tl militates against their use 30 yarn, has a circular cross-section and contains 1% T10 i t i d products, especially carpets Where not only and the other component, forming the remaining 20% of i an tiili efl t desirable but also bright shiny the yarn, has a trilobal cross-section and contains 0.02% colours are required. Ti02- Since thechalky appearance f th yam becomes i. Yarns may advantageously comprise filaments having dent ailBZZiin s of delustrant below that required to give ff n deniers within either or both componentssignificant anti-soiling effects, a compromise between the The invention also includes carpets formed from the anti-soiling effect, at high delustrant level, and chalkiness above-mentioned yarns. of colour is almost impossible to achieve. Thus, for ex- The invention is illustrated by the following examples. ample, when using titanium dioxide as the delustrant in 40 polyamides, chalkiness makes its appearance at a level EXAMPLE 1 gi ggsfg gfg yfgfgg Slgmficant sollmg effect 15 6 samples of carpets, A, B, C, D, E and F, were pre- We have now found, however, that a small percentage Pared- 3 samples" were from PPIYhGXa' of very bright filaments blended with a heavily delustred methylene adlpamlde Staple fibre yarns m a cut P tufted yarn can break down this chalky background and give a construction, and the other 3, E and from eohtlmb brighter surface appearance, especially when utilised in 0118 filament PolyheXamethylene adipamide yams, hhlked t by the well known stuffer-box crimping technique. De-

Accordingly therefore, the present invention provides tails of the carpets and of yarn construction are given a yarn comprising not less than of delustred filain Table 1.

TABLE 1 Type of yarn used Carpet v identification Yarn count Percent of the delustred component Percent of the bright component A 100% nylon staple made from polymer None.

with 1% TiOz circular cross section. 2/54 yarn spun on Mackie system from 12 B denier 4-6" variable length nylou staple 100% nylon staple made from polymer Do.

fibre. with 0.3% T10 circular cross section. 0 nylon staple made from polymer with 15% nylon staple made from polymer with 1% T10 circular cross section. less than 0.02% TiOz ti'ilobal cross section. D 109D%0nylon {made from tpolymer with 1% None.

Continuous filament crimped yarn total 1 mum at cross E '7 nylon yarn made fi om polymer with Do.

demer 3'650'204 filaments 0.2 T102 circular cross section. 1?. Continuous filament crimped yarn folded at 80% of nylon yarn from polymer with 1% 20% of nylon yarn made from polymer with crimping from 5 ends of 730/40 making T102 in four ends 01730/40 circular cross 0.02% TiOz in form of one end of 730/40 total after crimping of 3,650 denier 200 section; trilobal cross section.

filaments.

These carpets were dyed in 3 colours, namely, golden. Thesecarpets were.dyed in each of 3 colours,..namely, yellow, red and dark green. Comparisons of the colours golden yellow, red and dark green. Comparison of colours of the carpets showed that A and D were always less of these carpets showed that carpets L and M were much bright than the remaining B, C and E, F. The differences less bright than N and O. The difference in brightness bein brightness between carpets B and C or E and F were 5 tween carpets N and O was small but carpet O was slightvery small in all cases. Thus the addition of a small 1y brighter. In this case the increase in brightness obtained amount of a brighter component in a yarn with a high by addition of 33% of yarn with the delustrant content titanium dioxide content provides a degree of brightness of 0.2% was smaller than that obtained with 15% and similar to that obtained with yarns of generally low total 20% of yarn W th almost nil delustrant content (i.e. less delustrant content B and E. than 0.02% TiO quoted in Examples 1 and 2 above re- Samples of the above carpets in the white, undyed spectively. I state were laid in a corridor carrying a large volume of Samples of the above carpets in the White undyed state traflic. After a period Of 2 m nths, differences in rate of were laid in a corridor carrying a large volume of traflic soiling were apparent. The carpets formed from the yarns for 90 working days. containing a low total delustrant content, B and E, showed The difference in soiling by visual observation was apa Significantly greater degree of soiling than the four parent after 30 days. Carpets L and M appeared cleaner carpets A and C of D and which were famed from than N and O. The diiference between L and M was very yarns contai ning high delustrant content. The differences ll Carpet N was li h more dirty, and Carpet 0 was in soiling hetwem carpets A and C between D and F definitely worst. After 90 days of wear, carpet L and M were marglnalwere still significantly cleaner than N and 0 but the dif- EXAMPLE 2 ference between N and 0 had almost disappeared.

4 carpets, G, H, I and K, were made from pol'yhexa- The soiling of these carpets was measured using SAD methylene adipamide staple fibre yarn in a cut pile tufted (soiling additional density) method described by J. Lord construction; details of the carpets and yarn construction and W. H. Reese in the Journal of Textile Institute 1960, are given in Table 2. vol. 51, T.4l9, where SAD=log R /R R being percent TABLE 2 Type of yarn used Carpct identification Percent and type of delustred component Percent and type of bright component Yarn count and construction G 80% nylon staple made from polymer with 26% nylon staple made from polymer with 2/54 yarn spun on Mackie system from 12 1% T102 trilobal cross section. 0.01% T102 trilobal cross section. denier variable length 46 staple fibre.

H 80% nylon staple made from polymer with 20% nylon staple made from polyi-nerwith Do.

1.3% T102, trilobal cross section. 0.01% TiOz trilobal cross section.

I 100% nylon staple made from polymer with None Do.

1% T102, trilobal cross section.

K 100% nylon staple made from polymer with do Do.

0.3% T102, circular cross section.

These carpets were dyed in each of 3 colours, namely, 40 green reflectance of light measured in a clean carpet cirgolden yellow, red and dark green. Comparison of colours cle and R being the same measurement on a circle from of these carpets showed that carpet I was less bright than soiled carpet. The instrument used was the Colormaster e rfimainhlg H and The differences in g t e Model V made by Meeco Instrument Manufacturers, Enbetween carpets G H and K were small in all cases. Thus gineering & E i t Corporation, W i t' 1 i a sfnan {amount of a brighter component U.S.A. For each case two circles were tested and an aver- 111 a Y wlth a hlgh 2 Content G and H Provldes a age value for SAD taken. Table 4 shows the results for degree of brightness similar to that obtained with yarns L, M, N and O carpets measured after 24 and 90 soiling of generally low total delustrant content K. days.

Samples of the above carpets in the white uudyed state TABLE 4 were laid in a corridor carrying a large volume of traffic.

After a period of 2 months, dilferences in rate of soiling SAD for carpets were apparent. The carpet made from yarn with low Number otsouin days L M N 0 total delustrant content K showed a s gnlfica ly gr Mam days M82 M M71 M96 degree of SOlllng than the three carpets G, H and I mad Alter days 0.314 0.300 0,334 0,333

t yams .w1th.1i1gher average g g a 2: 55 The instrument assessment of soiling confirms the visdlffehences m solhng betweenvcarpe S an We ual assessment that L and M carpets were cleaner than marginal EXAMPLE 3 N and O and that the advantage of N carpet (blended yarn) over 0 carpet made of low delustred yarn 4 Carpets, N and 0 were made from polyhexfl' after 24 days disappeared after more prolonged soiling. lhfithylefle adl'pamide Continuous filament uhdyed Y 60 This experiment shows also that for high delustrant contuf ted Co struc i Details Of the Q p and Y tent yarns the efiect of cross-section, trilobal versus circustruction are given in Table 3. lar, is small. i

TABLE 3 Type of yarn used Carpet identification Percent and type of dclustred component Percent and type of bright component Yarn count and construction L 100% nylon yarn made from polymer with None Continuous filament crimped yarn tota 1% T102, trilobal cross section. denier 3,650 with 204 filaments. M 100% nylon yarn made from polymer with do 1% T102, circular cross section. N Approximately 67% of nylon yarn made Approximately 33% of nylon yarn made Continuous filament crimped yarn folded from polymer, with 1% TiOQ in 2 ends of from polymer with 02% T10: in one end at crimping from 3 ends of 1,210 denier 1,210 denier 68 filaments, trilobal cross of 1,210 denier-68 filaments of trilobal 68 filaments making total after crimping section. cross section. of 3,630 denier 204 filaments.

0 100% nylon yarn made from polymer with None Continuous filament crlmped yarn made 0.2% '1i02, trilobal cross section. p p v 7 v from 3,660 denier 204 filaments.

EXAMPLE 4 3 carpets P, R and S were made from polyhexamethylene adipamide staple fibre yarn in a cut pile tufted construction; details of the carpets and yarn construction are given in Table 5.

6 3. A yarn according to claim 2 wherein the polyamide is polyhexamethylene adipamide.

4. A yarn according to claim 1 wherein the delustrant is titanium dioxide and the bright yarn contains not more than 0.05% by weight of this delustrant.

TABLE Type of yarn used Carpet identification Percent and type of delustred component Percent and type of bright component Yarn count and construction P 18 denier 10%, 16 denier 70%, 12 denier 20%, all made from polymer with 1X T102, circular cross section.

all made from polymer with 0.2% Ti02, circular cross section.

None 2/54 yarn spun on Mackie system from variable 4-6 staple fibre.

l2 denier 22% made from polymer with 0.01% TiOz, trilobal cross section.

None

These three carpets were dyed in each of 2 colours, namely, pink and yellow golden.

In comparison, carpet P was much duller and less shiny than carpets R and S. The dilference in brightness between carpets R and S was small. Thus the addition of a small amount of a brighter component with practically nil delustrant R to yarn with high delnstrant content provides a degree of brightness similar to that obtained with yarn with a low total delustrant content S.

Samples of the above carpets in the white, undyed state were laid in a corridor carrying a large volume of traific. After a period of two months, difierences in the rate of soiling were apparent. The carpet made from yarn with low total delustrant content S showed a significant greater degree of soiling than the other two carpets P and R made from yarns with a total high delustrant content. The differences in soiling between carpets R and P were small, with P being marginally better than R.

What we claim is:

1. A yarn comprising not less than 70% of delust'red filaments containing not less than 0.7% by weight of a delustrant and not more than 30% of bright filaments COntaining les than 0.3% by weight of a delustrant.

2. A yarn according to claim 1 wherein the filaments are polyamide filaments.

References Cited UNITED STATES PATENTS 2,913,801 11/1959 Kessler 28-74(H) 3,480,582 11/1969 Brooks 57140BY DONALD E. WATKINS, Primary Examiner US. Cl. X.R. 57140J 

